Magnetic disk comprising a first carbon overcoat having a high SP3 content and a second carbon overcoat having a low SP3 content

ABSTRACT

A method for making a magnetic disk comprises forming first and second protective carbon layers on a magnetic layer. The first protective carbon layer is predominantly SP3 carbon. The second protective carbon layer comprises about 50% or less SP3 carbon. The second protective carbon layer is very thin, e.g. between 0.1 and 1.0 nm thick. A lubricant layer (e.g. a perfluoropolyether lubricant) is applied to the second protective carbon layer. The second protective carbon layer facilitates improved cooperation between lubricant and the disk.

BACKGROUND OF THE INVENTION

This invention pertains to methods for manufacturing magnetic diskscomprising carbon protective overcoats and the resulting magnetic disks.

FIG. 1 illustrates in cross section a magnetic disk 10 in a disk drive12. Magnetic disk 10 comprises a substrate 14 (e.g. glass, glassceramic, or NiP-plated aluminum), an underlayer 16 (e.g. Cr, a Cr alloy,NiP, NiAl or other appropriate material), a magnetic layer 18 (e.g. a Coalloy), and a protective overcoat 20 (e.g. hydrogen-doped carbon,nitrogen-doped carbon, or carbon doped with both hydrogen and nitrogen).A lubricant layer 22 (e.g. perfluoropolyether) is applied to protectiveovercoat 20.

Magnetic disk 10 is mounted on a spindle that is rotated by a motor 24.A read-write head 26, mounted on a suspension 28, “flies” above therotating disk. Head 26 comprises a slider including a hard Al₂O₃—TiCbody 30 with a read-write element 32 formed on the trailing edgethereof. A carbon overcoat 34 is formed on the bottom surface (the airbearing surface) of head 26 for tribological purposes.

Magnetic layer 18 performs the function of storing data. Overcoat 20performs several functions:

a) It prevents corrosion of magnetic layer 18.

b) It is hard, and prevents mechanical damage of magnetic layer 18.

c) It exhibits low static and dynamic friction.

d) It holds lubricant layer 22 on disk 10.

e) It prevents wear of disk 10.

Industry has devoted a large amount of time and effort trying to formappropriate carbon films to be deposited on magnetic disks as protectivelayers. For example, F. K. King, “Datapoint Thin Film Media”, IEEETrans. Magn., July 1982, discuses sputtering carbon on a magnetic disk.U.S. Pat. No. 5,045,165, issued to Yamashita, discusses sputtering ahydrogen-doped carbon film on a magnetic disk to prevent wear andcorrosion. Yamashita teaches that the hydrogen enhances wear resistanceof the carbon. European Patent Application EP 0 547 820 discussessputtering a nitrogen-doped carbon film on a magnetic disk. The '820application states that the nitrogen reduces stress in the carbon, andreduces the likelihood that the carbon will delaminate from the disk.U.S. Pat. No. 5,837,357 discusses a magnetic disk comprising ahydrogen-doped carbon film covered by a nitrogen-doped carbon film. U.S.Pat. No. 5,232,570 also discusses sputtering carbon on the magnetic diskin the presence of nitrogen. Other references pertaining to carbonovercoats for magnetic disks include U.S. Pat. No. 5,855,746 and PCTPatent Application WO 99/03099. This list is by no means exhaustive.

Protective carbon overcoats for magnetic disks are typically formed bysputtering. Because of the way in which they are formed, they comprisemostly SP2 carbon. Industry has been using such carbon films for manyyears, and has considerable experience with these films. Thus, varioustypes of lubricants have been developed which can be applied topredominantly SP2 carbon films to cause these films to exhibit lowfriction and stiction. (As used herein, the term “predominantly SP2carbon” means that of the carbon bonds in the film, more of those bondsare SP2 than any other type of bond. Similarly, “predominantly SP3carbon” means that of the carbon bonds in the film, more are SP3 thanany other type of bond.)

Recently, Komag (the assignee of the present invention) developed a newtype of carbon overcoat comprising more than 70% SP3 carbon. This typeof carbon overcoat is described by Wen Hong Liu et al. in U.S. patentapplication Ser. No. 09/298,107 now U.S. Pat. No. 6,086,730, filed onApr. 22, 1999, incorporated herein by reference. The '107 carbon isdeposited by applying a novel voltage waveform to carbon sputteringtargets. It has been discovered that this carbon overcoat is extremelyhard and scratch resistant.

There are other types of carbon overcoats that have high SP3 contents.In particular, one can form a carbon film using chemical vapordeposition, ion beam deposition, or cathodic arc deposition. Weiler etal., “Deposition of Tetrahedral Hydrogenated Amorphous Carbon Using aNovel Electron Cyclotron Wave Resonance Reactor”, Applied PhysicsLetters, Vol. 72, No. 11, Mar. 16, 1998, discusses ion beam depositionof carbon. Kang, et al., “Evaluation of the Ion Bombardment Energy forGrowing Diamondlike Carbon in an Electron Cyclotron Resonance PlasmaEnhanced Chemical Vapor Deposition”, J. Vac. Sci. Technol. A. 16(4),July/August 1998, discusses using chemical vapor deposition to form acarbon film. J. Robertson, “Ultrathin Carbon Overcoats for MagneticStorage Technology”, TRIB-Vol. 9, Proceedings of the Symposium onInterface Technology Towards 100 Gbit/in², ASME 1999 discusses cathodicarc deposition. Other references include U.S. Pat. No. 5,476,691; Brown,“Vacuum Arc Ion Sources”, Rev. Sci. Instrum. 65(10), October 1994,Sanders, et al., “Coating Technology Based on the Vacuum Arc—a Review”,IEEE Transactions on Plasma Science, Vol. 18, No. 6, 1990; and Anders etal., Mechanical Properties of Amorphous Hard Carbon Films Prepared byCathodic Arc Deposition”, Mat. Res. Soc. Symp. Proc. Vol. 383, 1995.Japanese laid-open publication 62-183022 discusses using a plasma CVDprocess to make a carbon film on a magnetic disk. Weiler, Kang,Robertson, the '691 patent, Brown, Sanders, Anders, and the 62-183022references are incorporated herein by reference.

SP3 carbon has an atomic structure that differs from SP2 carbon.Accordingly, the behavior of SP2 carbon can be quite different from SP3carbon—sometimes to an unpredictably great extent.

As mentioned above, magnetic disk drive 12 contains magnetic disk 10with carbon protective overcoat 22 and lubricant 24 applied to the disk.The disk substrate 14 is textured to minimize friction and stictionbetween disk 12 and read-write head 26. The disk/read-write headinterface constitutes a finely tuned tribological system designed tominimize static and dynamic friction and wear. The texturing of thedisk, the composition, deposition conditions and structure of carbonprotective overcoats 22 and 34, the other elements added to the carbonovercoats, the types of lubricants, the additives in the lubricants,lubricant application process and related parameters are determinedbased on exhaustive research to ensure that the disk drive can survive alarge number of on/off (contact-start-stop, or “CSS”) cycles. Changingone element in this tribological system can alter the behavior of theentire system. For example, if one were to replace a conventional typeof predominantly SP2 carbon with a different type of carbon, e.g. apredominantly SP3 carbon, that can completely change the behavior of thetribological system.

Merely by way of example, it has been discovered that when one tries touse the '107 type carbon and a perflouropolyether lubricant such asZ-dol (manufactured by Montedison Co. of Italy) mixed with an X1Padditive, for reasons not well understood, the resulting disks tend tofail glide tests. This is particularly interesting and unexpected, sincethe lubricant thickness is only about 3 nm, whereas the glide testing isperformed at a glide height of about 1 microinch, or about 25 nm. Thus,it is highly unexpected that the lubricant could interact with thecarbon film in such a way as to cause a failure in a glide test wherethe glide height is eight times the lubricant thickness.

Certain forms of high SP3 carbon formed by chemical vapor depositionhave been found to exhibit other problems, i.e. sensitivity to certaintypes of contaminants.

SUMMARY

A method in accordance with the invention comprises depositing first andsecond carbon layers on a magnetic disk and then applying a lubricant tothe magnetic disk. In one embodiment, the first carbon layer ispredominantly SP3 carbon. The first layer can have 70% or greater SP3bonding. The second layer comprises less than or equal to 50% SP3bonding. The second layer can be extremely thin, e.g. a flash layer ofhaving a thickness between 0.1 and 1 nm. The lubricant can be aperfluoropolyether lubricant.

Of importance, the high SP3 content protective layer is extremely hard,and resists wear and scratching. Because the second protective layer isso thin, it does not add substantially to the separation of the magneticfilm within the disk and the read-write head.

It has further been discovered that although the second protective layeris extremely thin, the properties of the second protective layer controlthe manner in which the lubricant cooperates with the disk. Inparticular, although the second carbon layer is only 0.1 to 1 nm thick,the lubricant bonds with, and adheres to the second carbon layer in thesame way that the lubricant would cooperate with the carbon on aconventional magnetic disk. The second carbon layer can mask anydeleterious effects that the high SP3 content of the first carbon layerwould otherwise have on the disk's interaction with the lubricant.

As mentioned above, the first and second carbon layers have differentstructures. Because the first carbon layer has mostly SP3 bonds, it hasa density greater than about 2.1 grams/cc, and typically about 2.5grams/cc. In contrast, the second carbon layer has a lower density, e.g.less than about 2.1 grams/cc, and typically 1.8 grams/cc.

The first carbon layer has a refractive index that is greater than 2.0,and typically about 2.1. The second carbon layer has a lower refractiveindex than the first carbon layer, less than about 2.0 and typicallyabout 1.8.

In one embodiment, the first carbon layer has a lower surface energythan the second carbon layer. (One way of measuring the surface energyis by a water contact energy test. The difference in water contact anglebetween the first and second carbon layers can be greater than 3 degreesand in one embodiment, greater than about 5 degrees. This difference inwater contact angle is typically less than about 8 degrees.)

In accordance with another aspect of the invention, a new type of carbonovercoat is introduced into the manufacturing process for a magneticdisk without requiring the exhaustive optimization and reengineeringthat normally occurs when one makes a change to one of the elements ofthe tribological system of the disk and read-write head. In accordancewith this aspect of the invention, a process for manufacturing amagnetic disk initially comprises the steps of:

a) providing a structure comprising a substrate with a magnetic layerthereon;

b) depositing a first carbon overcoat on the magnetic layer (e.g. apredominantly SP2 carbon overcoat formed by sputtering); and

c) applying a lubricant layer on the protective overcoat. A method inaccordance with the invention comprises replacing the step of depositingthe first carbon overcoat with the step of providing a carbon overcoathaving characteristics that are different from those of the firstovercoat (e.g. an overcoat with predominantly SP3 carbon), followed bythe step of a depositing a very thin layer of carbon using the same orsubstantially the same deposition conditions as those used to form thefirst carbon overcoat. For example, the process gas composition,pressure, and flow rate are the same or substantially the same. Thesubstrate bias and temperature can be the same or substantially thesame. Thus, the top surface of the magnetic disk, comprising the verythin layer of carbon, cooperates with the lubricant in substantially thesame way as the above-mentioned first layer of carbon. Therefore, it isnot necessary to do the substantial testing and engineering work thatwould otherwise need to be done if one simply replaced the first carbonovercoat with a predominantly SP3 carbon overcoat.

The predominantly SP3 carbon overcoat can be formed using the method ofthe '107 patent, or it can be deposited by CVD or cathodic arcdeposition.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates in cross section a magnetic disk drive constructed inaccordance with the prior art.

FIG. 2 illustrates in cross section a magnetic disk constructed inaccordance with the present invention.

DETAILED DESCRIPTION

A process in accordance with the present invention comprises thefollowing steps. First, a substrate 100 (FIG. 2) is provided. Thesubstrate can be glass, glass ceramic, NiP-plated aluminum or othersubstrate material. Substrate 100 is then textured, e.g. usingmechanical, laser or chemical techniques. (Such techniques are wellknown in the art.)

One or more underlayers 102 (e.g. Cr, a Cr alloy, NiP, NiAl or othermaterial) is deposited, e.g. by sputtering, onto substrate 100.Underlayer 102 can be about 10 to 30 nm thick.

One or more magnetic alloy layers 104 (e.g. a Co or Fe alloy) isdeposited, e.g. by sputtering, onto underlayer 102. Magnetic layer 104can be about 15 nm thick. In one embodiment, underlayer 102 and magneticalloy layer 104 are formed using the method and materials described inU.S. patent application Ser. No. 08/874,753, now U.S. Pat. No. 5,928,282filed by Bertero et al. on Dec. 4, 1997 and incorporated herein byreference.

A first overcoat 108 a having a relatively high SP3 content is depositedon magnetic alloy layer 104. Overcoat 108 a is hard, and has, forexample, about 70% or more SP3 carbon, and typically about 80% or moreSP3 carbon, e.g. as measured by the reflection energy loss spectrometer(REELS) technique. (The REELS technique is described by Hsiao-chu Tsaiet al. in “Structure and Properties of Sputtered Carbon Overcoats onRigid Magnetic Media Disks”, J. Vac. Sci. Technol. A6(4), July/August1988, incorporated herein by reference.) Overcoat 108 a minimizes wear,mechanical damage and corrosion of the disk. Overcoat 108 a is typicallyabout 2 to 5 nm thick. In one embodiment, overcoat 108 a is formed usingthe sputtering method described in U.S. patent Ser. No. 09/298,107,filed by Wen Hong Lieu et al. on Apr. 22, 1999. In another embodiment,layer 108 a can be formed by chemical vapor deposition (CVD) orplasma-enhanced chemical vapor deposition (PECVD). During PECVD, ahydrocarbon gas such as ethylene or acetylene is introduced into thedeposition chamber and caused to decompose, e.g. by the application ofelectrical energy to the chamber. This results in the deposition of ahydrogen-doped carbon film on the magnetic disk.

Overcoat 108 a can be formed by other techniques, e.g. cathodic arcdeposition or ion beam deposition (IBD), e.g. as described in theabove-incorporated references.

A second overcoat 108 b is formed on and continuously covers firstovercoat 108 a, e.g. by sputtering. Second overcoat 108 b is anextremely thin “flash” layer, e.g. 0.1 to 1.0 nm thick. (As mentionedabove, this flash layer 108 b cooperates with a subsequently depositedlubricant layer. As used herein, the term “flash” layer means a layer ofsufficient thickness to adequately cooperate with the lubricant layer sothat the lubricant functions properly, but not substantially thickerthan that.) Overcoat 108 b has a much lower SP3 content than overcoat108 a, e.g. less than or equal to about 50%. In one embodiment, the SP3content is between 40 and 50%. Because of the difference in thestructures of overcoats 108 a and 108 b, they have differentcharacteristics. In one embodiment, carbon 108 a has a density of about2.5 grams/cc, as measured by XRR (x-ray reflectivity). Carbon 108 b hasa density of 1.8 grams/cc. Carbon 108 a has a refractive index, asmeasured by an ellipsometer, of 2.1, whereas carbon 108 b has arefractive index of 1.9.

In one embodiment, carbon 108 b is formed by sputtering using a processgas comprising an inert gas such as argon mixed with nitrogen.(Optionally, hydrogen can be included in the process gas.) The gaspressure is between 2 and 10 mTorr, typically between 4 and 9 mTorr, andpreferably between 6 to 9 mTorr. The argon flow rate is 50 to 90 SCCM,and the nitrogen flow rate is 4 to 10 SCCM. In some embodiments, bias isapplied to the substrate, but in other embodiments, bias is not appliedto the substrate. The power density is 1 to 2 W/cm². The deposition rateof carbon layer 108 b is typically substantially less than thedeposition rate for carbon layer 108 a. In particular, the depositionrate for carbon layer 108 a is typically between 0.1 and 2 nm/second,and preferably between 0.5 and 1 nm/second.

After carbon layer 108 b is formed, a lubricant layer 110 is applied tothe disk. The lubricant can be a perfluoropolyether lubricant. Anexample of such a lubricant is Fomblin Z-dol, sold by Montedison Co. ofItaly. An additive can be added to this lubricant. An example of such anadditive is polyphenoxycyclotriphosphazene, described in U.S. Pat. No.5,587,217, issued to Chao et al., incorporated herein by reference. Anadditive sold under the trade name X1P, manufactured by Dow ChemicalCorp. of Midland, Mich. can be used. The lubricant can be applied to thedisk by dipping the disk in a room temperature bath comprising a mixtureof the Fomblin Z-dol and X1P. The speed at which the disk is dipped intothe lubricant bath can be 1 to 2 mm/minute. Optionally, after thedipping process, the lubricant can be subjected to a baking process. Thethickness of the lubricant and additive on the disk is about 3.2 nm, outof which about 3 nm is Z-dol, and 0.2 nm is X1P as measured by the FTIRtechnique.

Formation of Carbon Layer 108 a by Sputtering

As mentioned above, carbon layer 108 a can be formed using the techniquedescribed in the '107 application. During one embodiment of this method,a graphite sputtering target us used. The process gas comprises argon,hydrogen and nitrogen. The argon gas flow is 50 to 70 SCCM, the nitrogengas flow is 0.5 to 2.0 SCCM and the hydrogen gas flow is 15 to 30 SCCM.The power density is about 1 KW/100 cm², i.e. about 10 W/cm². Biassupply to the substrate is minus 100 to minus 200 volts. Magnetronsputtering can be employed. Optionally, the substrate can be heated. Inone embodiment, sputtering apparatus such as an Anelva C-3010 sputteringapparatus can be used. Other apparatus, such as an Ulvac sputteringmachine can also be used. A power supply, e.g. an RPG model pulse powersupply made by ENI Inc. of Rochester, N.Y. can be used.

As described in the '107 Application, a unique voltage waveform isapplied to the sputtering target. This waveform comprises an initialpositive potential portion, e.g. a portion that can be about 300 volts.Thereafter, a negative voltage is applied to the target. The negativeportion of the waveform typically comprises a negative pulse followed bya steady state negative voltage. The negative pulse can have two orthree times the magnitude of the steady state negative voltage. It isbelieved that the large negative swing in the voltage applied to thetarget momentarily causes a high deposition rate and carbon atoms canhave much higher energy than they would have during conventionalsputtering. It is believed that this voltage waveform causes the newprotective overcoat to have a greater SP3 content, and exhibit greaterhardness, than typical sputtered carbon films. The waveform applied tothe sputtering target can have a frequency between about 50 kHz and 250kHz.

Formation of Carbon Layer 108 a by CVD

In one embodiment, carbon layer 108 a is formed by CVD (typicallyplasma-enhanced CVD, or PECVD) by applying 1000 Watts to the CVDapparatus, with a substrate bias of 300V and a process gas of C₂H₄(ethylene) flowing at a rate of 150 SCCM. The pressure in the depositionchamber is typically between about 20 to 40 mTorr. The process time isabout 5 seconds, and results in 5 nm of predominantly SP3 carbon. Thesubstrate is not heated in this particular example of a CVD process. Thedetails for this process are merely exemplary. Other carbon-containingprocess gases and other parameters can also be used.

Modification of a Pre-existing Manufacturing Process

As mentioned above, a read-write head and magnetic disk form a carefullyengineered tribological system designed to minimize friction andstiction between the read-write head and the disk, minimize wear, andmaximize the number of contact-start-stop (CSS) cycles that the diskdrive can survive. A great amount of engineering effort is required toaccomplish these goals. This engineering effort includes:

a) Providing an appropriate disk texture having texture features of anappropriate size, shape and a real density.

b) Providing an appropriate protective overcoat composition (both on thedisk and the read-write head). This involves developing an appropriatecomposition, thickness and morphology and selecting a deposition processfor the overcoat (e.g. CVD, sputtering, cathodic arc deposition or IBD).This also requires determining an appropriate process gas composition, aflow rate for each component of the process gas, process gas pressure,substrate bias and substrate temperature.

c) Providing a lubricant composition, thickness and applicationtechnique. This also involves selecting additives for the lubricant(including selecting the concentration of the additives), and developingappropriate lubricant application parameters. (For example, for adipping process, this includes selecting the rate at which the disk isdipped into and withdrawn from the lubricant bath and the bathtemperature.)

Replacing one type of protective overcoat on the disk with anotherprotective overcoat can have a deleterious effect on the rest of thetribological system. For example, providing a new carbon overcoat on thedisk may cause the disk to fail to cooperate properly with thelubricant.

In accordance with one embodiment of the invention, a method is providedfor altering a magnetic disk manufacturing process. The processinitially comprises one or more of the steps of:

a) providing a substrate (e.g. a glass substrate, a glass ceramicsubstrate, a NiP-coated aluminum substrate, or other appropriatesubstrate material);

b) providing an underlayer on the substrate (e.g. Cr, a Cr alloy, NiP,NiAl, or other appropriate underlayer deposited by sputtering);

c) providing a magnetic layer on the underlayer (e.g. a sputtered Co orFe alloy);

d) providing an initial protective overcoat on the substrate (e.g. acarbon film sputtered in the presence of nitrogen and/or hydrogen);

c) applying a lubricant to the protective overcoat (e.g. aperfluoropolyether lubricant applied by dipping.

Merely by way of example, the process described in theabove-incorporated '753 Bertero application can be used to form theunderlayer and magnetic layer. The protective overcoat can be formed bysputtering using the same sputtering conditions as those described forcarbon layer 108 b above. (In such an embodiment, the power applied tothe deposition chamber is typically greater than the above-mentioned 1to 2 W/cm² in order to obtain an appropriately high deposition rate.)The lubricant can be the above-mentioned Z-dol-X1P mixture applied bydipping, having a total thickness of about 32 nm.

In accordance with this method, the step of depositing the protectiveovercoat is replaced with the step of:

a) depositing a first, predominantly SP3 carbon overcoat on the magneticlayer; and

b) depositing a second carbon overcoat on the first carbon overcoat.

The first, predominantly SP3 carbon overcoat can be deposited using thedeposition techniques and conditions described above for carbon layer108 b. The first carbon overcoat can be about 2 to 5 nm thick. Thesecond carbon overcoat can be deposited by sputtering using the same orsubstantially the same conditions (e.g. the same or substantially thesame process gas composition, flow rates for the various components ofthe process gas and process gas pressure) as for the initial protectiveovercoat that is being replaced. The substrate bias and/or substratetemperature can also be the same or substantially the same duringdeposition. (Typically, the power applied to the sputtering apparatusduring deposition of the second carbon overcoat is less than the powerused to deposit the initial protective overcoat. This facilitates aslower deposition rate for the second carbon overcoat.) Of importance,the second carbon overcoat has the same or substantially the samecomposition (including the same or substantially the same hydrogenand/or nitrogen content) and/or morphology (e.g. SP2 and SP3 content) asthe initial protective overcoat. Further, the second carbon overcoatcooperates with the lubricant layer in the same or substantially thesame way as the initial protective overcoat. Thus, even though theinitial protective overcoat is being replaced with a dual layerstructure comprising mostly SP3 carbon having a structure that differsfrom the initial protective overcoat, the second carbon overcoat masksthis mostly SP3 carbon, and provides a continuous carbon surface thatbehaves and cooperates with the lubricant and/or other components of thesystem (e.g. texture, slider surface, etc.) in the same way as theinitial protective overcoat. Thus, one can replace the initialprotective overcoat with this new, mostly SP3 carbon, without having toengage in substantial reengineering of the head-disk tribologicalsystem.

Industrial Application

A disk constructed using a method in accordance with the presentinvention is typically incorporated into a disk drive. The disk iscoupled to a motor via a spindle. The motor rotates the disk rapidly,while a read-write head “flies” above the disk drive. The read-writehead is held in place by a suspension.

While the invention has been described with respect to specificembodiments, those skilled in the art will recognize that changes can bemade in form and detail without departing from the spirit and scope ofthe invention. For example, the process gas used to form layer 108 b caninclude between 0 and 20% nitrogen, 0 and 20% hydrogen in addition to aninert gas. In some embodiments, the SP3 content of layer 108 b isbetween 30 and 60%, but still substantially less than the SP3 content oflayer 108 a. The various layers (102 to 110) can be formed on one orboth sides of substrate 100. Accordingly, all such changes come withinthe present invention.

We claim:
 1. A method for making a magnetic disk comprising: depositinga first carbon layer on said disk, said first carbon layer comprisingpredominantly SP3 carbon; depositing a second carbon layer on said disk,said second carbon layer comprising about 60% or less SP3 carbon, theSP3 content of the second carbon layer being less than the SP3 contentof the first carbon layer, said second carbon layer being amorphous; anddepositing a lubricant layer on said second carbon layer.
 2. Method ofclaim 1 wherein the second carbon layer comprises less than about 50%SP3 carbon.
 3. Method of claim 2 wherein the second carbon layercomprises more than about 30% SP3 carbon.
 4. Method of claim 1 whereinsaid second carbon layer has a thickness less than or equal to about 1nm.
 5. Method of claim 1 wherein said second carbon layer is between 0.1and 1 nm thick.
 6. Method of claim 1 wherein the second carbon layer isformed by sputtering and the first carbon layer is formed by CVD, PECVD,IBD or cathodic arc deposition.
 7. Method of claim 1 wherein the firstand second carbon layers are formed by sputtering.
 8. Method of claim 7wherein said depositing of said first carbon layer comprises: applying avoltage to a sputtering target, said sputtering target comprisingcarbon, said voltage being applied by a power supply in the form ofpulses, said pulses comprising at least a first portion and a secondportion, the voltage applied during said second portion being morenegative than that applied during said first portion, wherein a firstsub-portion of said second portion is more negative than a secondsub-portion of said second portion.
 9. Method of claim 1 wherein saidsecond carbon layer is non-particulate.
 10. A method for modifying amanufacturing process, said manufacturing process comprising providing acarbon-based protective overcoat on a magnetic disk using a set ofparameters, said method comprising modifying said process such thatinstead of providing said carbon-based protective overcoat on saidmagnetic disk using said set of parameters, the following acts areperformed: depositing a first carbon layer on said magnetic disk, saidfirst carbon layer having an SP3 content of at least about 70%; anddepositing a second carbon layer using substantially said set ofparameters, said second carbon layer being less than or equal to about1.0 nm thick, and wherein after said depositing of said first and secondcarbon layers using said modified process, a lubricant layer is appliedto said second carbon layer.
 11. Method of claim 10 wherein said firstcarbon layer has a thickness between 2 and 5 nm.
 12. Method of claim 10wherein said depositing of said second carbon layer comprises sputteringsaid second carbon layer in a sputtering chamber and said parametersinclude the composition and pressure of the gas in the sputteringchamber.
 13. Method of claim 10 wherein said parameters include thesubstrate temperature and bias voltage.
 14. Method of claim 10 whereinsaid second carbon layer has a thickness greater than or equal to about0.1 nm.
 15. Method of claim 10 wherein said first carbon layer comprisesat least one material selected from the group consisting of nitrogen andhydrogen.
 16. Method of claim 10 wherein said second carbon layercomprises at least one material selected from the group consisting ofnitrogen and hydrogen.
 17. Method of claim 10 wherein said second carbonlayer comprises less than 60% SP3 carbon.
 18. Method of claim 10 whereinsaid second carbon layer is amorphous.
 19. Method of claim 10 whereinsaid first carbon layer has a thickness less than 5 nm.
 20. Method ofclaim 10 wherein said second carbon layer is non-particulate.
 21. Amethod for modifying a manufacturing process, said manufacturing processcomprising providing a carbon-based protective overcoat on a magneticdisk using a set of parameters, said method comprising modifying saidprocess such that instead of providing said carbon-based protectiveovercoat on said magnetic disk using said set of parameters, thefollowing acts are performed: depositing a first carbon layer on saidmagnetic disk, said first carbon layer comprising predominantly SP3carbon; and depositing a flash layer of carbon using said set ofparameters, and wherein after said depositing of said first and flashcarbon layers using said modified process, a lubricant layer is appliedto said flash layer, and wherein said flash layer has a thickness lessthan about 1 nm.
 22. Method of claim 21 wherein said first carbon layercomprises about 70% or more SP3 carbon.
 23. Method of claim 21 whereinsaid first carbon layer comprises at least one material selected fromthe group consisting of hydrogen and nitrogen.
 24. A method formodifying a manufacturing process, said manufacturing process comprisingproviding a carbon-based protective overcoat on a magnetic disk using aset of parameters, said method comprising modifying said process suchthat instead of providing said carbon-based protective overcoat on saidmagnetic disk using said set of parameters, the following acts areperformed: depositing a first carbon layer on said magnetic disk, saidfirst carbon layer comprising predominantly SP3 carbon; and depositing aflash layer of carbon using said set of parameters, and wherein aftersaid depositing of said first and flash carbon layers using saidmodified process, a lubricant layer is applied to said flash layer, andwherein said flash layer comprises at least one material selected fromthe group consisting of hydrogen and nitrogen.
 25. A method formodifying a manufacturing process, said manufacturing process comprisingproviding a carbon-based protective overcoat on a magnetic disk, saidmethod comprising modifying said process such that instead of providingsaid carbon-based protective overcoat on said magnetic disk, thefollowing acts are performed: depositing a first carbon layer on saidmagnetic disk, said first carbon layer comprising predominantly SP3carbon; and depositing a second carbon layer that cooperates withlubricant with substantially the same effectiveness as said protectiveovercoat, wherein said second layer is less than about 1 nm thick. 26.Method of claim 25 wherein said first carbon layer has an SP3 content ofabout 70% or more.
 27. Method of claim 25 wherein said second carbonlayer has substantially the same SP3 content as said protectiveovercoat.
 28. Method of claim 25 wherein said second carbon layer hassubstantially the same density and refractive index as said protectiveovercoat.
 29. Method of claim 25 wherein said second carbon layer hassubstantially the same surface energy as said protective overcoat. 30.Method of claim 25 wherein said second carbon layer has substantiallythe same chemical properties as said protective overcoat.
 31. Method ofclaim 25 wherein said second carbon layer comprises at least onematerial selected from the group consisting of hydrogen and nitrogen.32. Method of claim 25 wherein said first carbon layer comprises atleast one material selected from the group consisting of hydrogen andnitrogen.
 33. Method of claim 25 wherein said second carbon layer is aflash layer.
 34. Method of claim 25 wherein without said second carbonlayer, the cooperation between said lubricant layer on said first carbonlayer would be such as to tend to cause said disk to fail a glide heighttest, and wherein said second carbon layer permits said magnetic disk topass said glide height test.
 35. Method of claim 34 wherein said glideheight test tests said disk at a height of about 1 microinch.
 36. Methodof claim 25 wherein said first carbon layer has a greater SP3 contentthan said second carbon layer.
 37. Method of claim 25 wherein said diskcan pass a glide height test at 1 microinch.
 38. A method for modifyinga manufacturing process, said manufacturing process comprising providinga carbon-based protective overcoat on a magnetic disk, said carbon-basedovercoat comprising one component of a head-disk interface, said methodcomprising modifying said process such that instead of providing saidcarbon-based protective overcoat on said magnetic disk, the followingacts are performed: depositing a first carbon layer on said magneticdisk, said first carbon layer comprising predominantly SP3 carbon; anddepositing a second carbon layer that cooperates with at least onesecond component of said head-disk interface with substantially the sameeffectiveness as said protective overcoat, wherein said second componentof said head-disk interface comprises one or more of: a lubricantapplied above said second carbon layer, a texture formed on said disk,and a slider having a read element thereon, wherein said second carbonlayer is amorphous.
 39. Method of claim 38 wherein said second componentcomprises said lubricant applied above said second carbon layer.
 40. Amethod for modifying a manufacturing process, said manufacturing processcomprising providing a carbon-based protective overcoat on a magneticdisk using a set of parameters, said method comprising modifying saidprocess such that instead of providing said carbon-based protectiveovercoat on said magnetic disk using said set of parameters, thefollowing acts are performed: depositing a first carbon layer on saidmagnetic disk, said first carbon layer comprising predominantly SP3carbon; and depositing a flash layer of carbon using said set ofparameters, and wherein after said depositing of said first and flashcarbon layers using said modified process, a lubricant layer is appliedto said flash layer, wherein said flash layer of carbon is amorphous.41. A method for modifying a manufacturing process, said manufacturingprocess comprising providing a carbon-based protective overcoat on amagnetic disk, said method comprising modifying said process such thatinstead of providing said carbon-based protective overcoat on saidmagnetic disk, the following acts are performed: depositing a firstcarbon layer on said magnetic disk, said first carbon layer comprisingpredominantly SP3 carbon; and depositing a second carbon layer thatcooperates with lubricant with substantially the same effectiveness assaid protective overcoat, wherein said second carbon layer is amorphous.